Independently variable stroke multiple needle tufting machine



J- H. BOYLES Nov. 22, 1966 INDEPENDENTLY VARIABLE STROKE MULTIPLE NEEDLE TUFTING MACHINE Filed Nov. 28, 1958 4 Sheets-Sheet 1 IN VENTOR: JOHN H. BOYLES ATTORNEY Nov. 22, 1966 J. H. BOYLES 3,286,670

INDEPENDENTLY VARIABLE STROKE MULTIPLE NEEDLE TUFTING MACHINE Filed Nov. 28, 1958 4 Sheets-Sheet 2 INVENTORC JOHN H. BOYLES ATTORNEY Nov.-22, 1966 J. H. BOYLES 3,

INDEPENDENTLY VARIABLE STROKE MULTIPLE NEEDLE TUFTING MACHINE Filed Nov. 28, 1958 4 Sheets-Sheet S INVENTOR: JOHN H. BOYLES BY /mt AT-TORNEY J. H. BOYLES Nov. 22, 1966 INDEPENDENTLY VARIABLE STROKE MULTIPLE NEEDLE TUFTING MACHINE 4 Sheets-Sheet 4 Filed Nov. 28, 1958 FIG. 4

FIG. 5

INVENTOR. JOHN H. BOYLES BY 5M;

ATTORNEY United States Patent 3,286,670 INDEPENDENTLY VARIABLE STROKE MULTIPLE NEEDLE TUFTING MACHINE ohn H. Boyles, Rte. 4, Dalton, Ga. Filed Nov. 28, 1958, Ser. No. 777,071 28 Claims. (Cl. 112-266) This invention relates to an independently variable stroke multiple needle tufting machine.

While various aspects of the inventive concept are broadly applicable to a wide variety of sewing, stiching, tufting and chenille machines, the present embodiment of the invention is particularly concerned with the provision of apparatus embodying automatically controllable means for selectively varying the length of stroke of the thread carrying needle of a multiple needle machine so as to selectively produce varying design characteristics through the production of variously characterized lengths of loops formed by the individual needles.

In the tufting industry many and varied designs of utilitarian as well as artistic merit may be achieved by individual selection in the length of the pile formed in looped pile fabric. Considerable difficulty has been encountered in efforts to provide automatically controllable means for the selective formation of varying loop lengths in the commercial production of pile fabrics by a single continuously operating multiple needle tufting machine. By the method of my prior application, Serial No. 270,970 filed February 11, 1952 now US. Patent No. 2,876,441, entitled, Method and Means for Feeding Thread in Tufting Machines, a practical and commercially successful procedure has been set forth which has obtained substantial acceptance in the industry. By the method of my prior application fabrics of selectively varying pile heights are achieved by forming a loop of tufts of uniform extent; however, after formation of the uniform loop the yarn thereof is selectively tensioned to withdraw .a portion of the loop to reduce the length of the loop as desired whereby a predetermined design may be formed by such selective extent of loop lengths.

The present method and apparatus is designed to obtain alike objective by the production of selectively controlled loop lengths, for either cut or looped pile, through the use of selectable means for controlling the individual length of needle thrust. In this manner, loops of individually predetermined and preselected length may be formed without the requirement of the subsequent withdrawal operation of my prior invention. The present invention therefore provides an improved apparatus and method which is effective and efficient and which lends itself to economies in operation as well as in the cost and maintenance of the equipment required.

It is therefore among the objects of the invention to provide a novel and improved method of and means for the formation of a pile fabric in which the lengths of the pile loops differ to produce useful and artistic design characteristics.

Another object of the present invention is to provide a method and apparatus for forming pile fabric by automatic and continuous predetermined selection of loop characteristics, particularly with respect to the length of the loop, so as to provide for the automatic continuous formation of pile fabric of predetermined design characteristics.

Another object of the present invention is to provide for the continuous and automatic formation of a predetermined design of a pile fabric, the loops of which are of varying length by the use of apparatus and procedure in which the original formation of the loop is variable as to length and independent of any subsequent tensioning or withdrawal of loop material formed in the operation.

Patented Nov. 22, 1966 Another object of the present invention is to provide a sewing machine particularly of the type designed for the formation of pile fabric in which the length of needle thrust may be selectively varied, the invention being particularly applicable to multiple needle machines for the tufting of pile fabric.

Another object of the present invention is to provide means for the predetermined selective engagement of a needle bar by operating means of variable amplitudes of motion whereby the needle thrust may be adjusted in accordance with predetermined pattern control mechamsm.

It is also an object of the present invention to provide apparatus of the character described in which single means may be effected to selectively operate a needle with selectively variable amplitude of motion, the invention being particularly adapted for use in the formation of pile fabric whereby the needles may be selectively controlled to variably determine the length of loop formed thereby.

Another object of my invention is to provide a machine of the class described in which the stroke of the needle may be varied without stopping the machine.

Another object of my invention is to provide a machine and method for producing a tufted fabric comprising cut and loop piles of varying height.

Another object of my invention is to provide a tufted fabric comprising long cut piles and short loop piles.

Another object of my invention is to provide a machine and method of sewing varied height piles in which the short pile may either be loop pile or cut pile.

Numerous other objects, features and advanta es of the present invention will be apparent from a consideration of the following specification taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a side elevation of one form of the present invention.

FIG. 2 is a vertical cross sectional View taken on line 22 of FIG. 1, illustrating one of the needles in fully elevated position and showing the needle engaged for the extended thrust movement.

FIG. 3 is a cross section similar to FIG. 2, illustrating the needle in fully depressed position under the control of the limited thrust connection therefor.

FIG. 4 is a detail fragmentary cross section taken on the line 4-4 of FIG. 1.

FIG. 5 is a similar detail fragmentary cross section taken on the line 5-5 of FIG. 1.

FIG. 6 is a detail fragmentary horizontal cross section taken on the line 6-6 of FIG. 3.

Referring to the drawings 'in which there is shown one form of the apparatus of the present invention, the structure as here represented includes a generally horizontal bed or table 10 supported by longitudinally extending side rails 11 and an intermediate supporting rail of generally T-formation 12. The ends of the rails 11 and 12 are secured, as by welding or the like, to vertical end standards 13, the upper ends of which constitute right and left hand housings 14 and 15, respectively. The left hand longitudinal side of the table 10, as shown in FIGS. 2 and 3, constitutes the feed side to which the base fabric, to be tufted, is supplied. Adjacent the input edge, the table 10 is cut away to provide a wind-ow 16 to accommodate the needles and the looper and cutter mechanism as hereinafter described. Mounted on the table 10 in a horizontal position thereover is a fabric support formed of a plurality of spaced, parallel fabric support bars 17 each having a portion of diminishing thickness at 18 in registration with the window 16 of the bed 10 to provide parallel needle receiving slots through which the needles may reciprocate, there being one such 3 slot for each needle. The bars 17 provide an otherwise continuous supporting surface for fabric, indicated at 19, which fabric is adapted to pass transversely of the apparatus under the needles to receive the individual loops formed by the passage of the needles therethrough. In considering these and like structural features of the present invention, it will be understood that such structures here set forth is of substantially conventional form following the dictates of present multiple needle tufting machine construction and design. Obviously this detailed presentation is by Way of illustration; and the invention, with respect to such structural aspects, may be modified as circumstances may dictate.

The present form Bill the apparatus includes a superstructure above the table 10, here shown as generally rectangular in transverse cross section and supported at its ends by and between the housings 14 and 15, as by welding or the equivalent. The superstructure includes a longitudinally extending top plate 20 having an intermediate longitudinally extending slot 21 through which the pitmans 22 project. A forward longitudinal slot 23 is also provided in top plate 20 through which the needle bars 24 project. The rear edge of the top plate 20- is extended downwardly to form a rear wall 25 defining a longitudinally extending aperture 26, permitting free access to the operating mechanism of the device. Wall 25 terminates in a lower Wall edge 27 to which the rear flange 28 of a bottom horizontal plate 30 may be secured by welding as indicated. The forward edge of the bottom plate 30 is provided with a flange 31 defining the rear edge of a lower needle bar slot 32, the slot being vertically aligned with the upper slot 23. The front edge of the slot 32 is defined by the inner terminal edge 33 of a horizontal flange 34 formed at the bottom of a front plate 35. The front plate 35 is secured, as by bolts 36, to a front depending flange 37 of the top 20 and defines a window 38 in general registration with the aperture 26 of the rear wall to provide thorough access for adjustment, repairs, maintenance and the like of operating instrumentalities.

Mounted on the lower face of the bottom plate 30 there are provided tandem pairs of vertical cylindrical sleeves 40 which receive upstanding posts 41 of a longitudinally extending presser foot 42. Set screws 43 are provided for adjustably securing the posts 41 in vertically telescopic relation within the sleeves 40. The forward edge 44 of the presser foot 42 is formed with a row of closely adjacent apertures 45. j are arranged in alignment with the spaces formed by the reduced portions 18 of the bars 17 so as to provide an opening through which the needles carry the tufting yarn into fabric 19.

Extending through the slot 23 of the top plate 20 and the slot 32 formed between the flange 31 and the front edge 33 there is provided a closely adjacent row of needle vbars 24, the number and spacing of which are determined by such considerations as the longiutdinal extent of the apparatus and the character of tufting material employed and other factors well within the knowledge of those skilled in the construction and design of multiple needle tufting machines of the general character herein set forth.

Each needle bar 24 is provided, at its lower end, with a conventional needle 51, the eye 52 of which receives the yarn 53. Each yarn 53 is received by its needle 51 from'a guide aperture 54 formed on an extended shoulder of the needle bar 51, the yarn 53 having previously passed through a guide aperture 55 of a thread guide block 56. The thread or yarn 53 is supplied to the guide aperture 55 of the 'block 56 from a spool (not shown) and passes through a tension device, indicated by the numeral 57. This tensioning device comprises a pair of aligned rods 200 which are spaced apart and carried at their ends by bars, such as bar 201. Each of these bars is pivotally mounted by a pivotal pin 202 so that The apertures 45 when the tension device is essentially aligned with the path of travel of the yarn 53, little tension is applied. If, however, the device is tilted, as shown in FIGS. 2 and 3, the greater the extent of tilting, the greater will be the tension applied to yarn 53.

Below slot 32 are the needle bar guide members which consist alternately of a pair of spaced opposed guide fingers 58 and an abutting spacer plate 50 such that an opening is defined by the rounded opposed nose portions of each pair of guide fingers 58 and the central portions of adjacent spacer plates 50. The guide fingers 58 and spacer plates 50 are retained in place by rods 59 which pass through the guide fingers 58 and spacer plates 50 and are secured at their ends to housings 14 and 15. It is to be noted that the opposed nose portions of guide fingers 58 are rounded so as to facilitate the tilting slightly of the needle bars 24 which pass through and reciprocate in the openings so provided.

At the upper end of each needle bar 24 there is provided a flat head 62 which projects above top plate 20 through slot 23. The lower inner and outer edges of head 62 are respectively provided with inner notch 60 and outer notch 61. Running adjacent all inner edges of head 62 for engagement by any of the inner notches, such as notch 60, is a low stroke, notch engaging rod 63. Similarly a high stroke, notch engaging rod 64 is provided adjacent all the outer edges of the heads 62 in a position to be engaged by any outer notch such as notch 61. It is to be noted, however, that the transverse distance between rods 63 and 64 is always less than the width of head 62 such that either the outer notch 61 or the inner notch 60 must be engaged by its adjacent rod 63 or 64. Thus it is seen that at all times each needle bar is selectively engaged by one or the other of such rods.

According to my invention, the outer rod 64 is reciprocated generally vertically at a relatively high amplitude while the rod 63 is reciprocated in synchronization to the reciprocation of rod 64 at a relatively lower amplitude. To accomplish this in a simple manner, I have provided a reciprocating [frame including a plurality of parallel reciprocatable rocker arms 65, each of which is pivoted at a position remote from the rods 63 and 64 along a common pivot shaft 66. Shaft 66 is appropriately mounted on pillow blocks 67 at the rear edge 68 of top plate 20. As will be pointed out in more detail hereinafter, the rods 63 and 64 are supported adjacent the front ends of rocker arms 65 in their spaced relationship so that upon pivoting of the rocker arms 65, up and down, each of the rods 63 and 64 will be reciprocated accordingly.

Referring now particularly to FIG. 6, it will be seen that across the front ends of rocker arms 65 there is a cross beam 69 which is milled out at spaced intervals to provide a plurality of slots in which are carried spacer plates 71. Plates 71 pass between the adjacent heads 62 so that each head is positively spaced from the next adjacent head 62. The front ends of spacer plates 71 are received in recesses in a front beam 70 and rods 72 secure the spacer plates 71 in place, respectively, in cross beam 69' and front beam 70.

From an examination of FIGS. 2, 3 and 6, it will be seen that the rods 63 and 64 pass through apertures in plates 71 and are retained the-rein in spaced relationship to each other. Thus, upon reciprocation of the rocker arms 65, the rods 63 and 64 will be reciprocated therewith; however, since rod 63 is closer to shaft 66, the distance travelled in a vertical direction by rod 63 will glways be less than the vertical distance travelled by rod For reciprocating the rocker arms 65, I have provided bearing pins in an intermediate portion of each rocker arm 65. Below the rocker arms 65 are the pitmans 22, the upper ends of which form yokes which journal the bearing pins 80. At the lower end of each pitman 22 is provided a large bearing 81 encompassing a circular cam 82 which is eccentrically mounted on a main drive shaft 83-. Each cam 82 is aligned along shaft 83 so that upon rotation of shaft 83 each pitman 22 will synchronously drive its bearing pin 80 upwardly and downwardly, thereby driving rocker arms 65 upwardly and downwardly about pivot shaft 66.

It is to be noted that at the bottom dead center position of cams 82, the rocker arms 65 are essentially in a horizontal position, as shown in FIG. 3, and when cam 82 is at top dead center, rocker arm 65 are at an acute angle with respect to a horizontal plane. It is, therefore, important in the present embodiment that notch 60 is positioned below notch 61 such that when cam 82 approaches top dead center, rods 63 and 64 will be generally aligned with notches 60 and 61, respectively, so that by movement of head 62 at this portion of the cycle, notch 60 may be caused to engage or disengage rod 63 as notch 61 disengages or engages rod 64, and vice versa. At the bottom dead center position, as shown in FIG. 3, if notch 60 engages rod 63, the needle 51 will be inserted a short distance into the fabric 19; however, if notch 61 is engaged by rod 64, the needle 51 will be inserted further into fabric 19 at the bottom dead center position.

The needle bar shifting mechanism or control means which determines, individually, whether the needle bars 24 are in a long stroke position, as illustrated in FIG. 2, or in a short stroke position as illustrated in FIG. 3, includes an upstanding plunger casing 120 seen in FIGS. 2 and 3. By means of bolts 122, this casing 120 is secured to upper flange 121 which projects from front plate 35. Housing 120 extends upwardly and over front beam 70 to provide a surface 123- adjacent the upper portion of the front edge 97 of each of heads 62.

A plurality of aligned recesses, such as recess 124, is provided in housing 120 respectively opposite heads 62 and each recess 124 communicates with an internal guide bore 125 axially aligned in housing 120 with the recess 124. Each guide bore 125 receive a plunger 96 which carries on its end a piston 94. The piston 94 rides in recess 124 and is urged outwardly against edge 97 by a compressed coil spring 95 therebe'hin-d, within recess 124. Thus it is seen that each of heads 62 is individually urged rearwardly of the machine so that under normal circumstances the notches, such as notches 60, will be engaged by rod 63 and hence when shaft 83 is rotating, each needle bar 24 will be re-ciprocated in a low stroke condition, as shown in FIG. 3.

Opposite the housing 120 and above over pitmans 22 is a solenoid supporting platform 130 which is supported in a horizontal plane above top plate 20 by mean of brackets 131 projecting up from housings 14 and 15. A plurality of solenoids 90 is mounted on platform 1.30 by means of bolts 132. Each solenoid is aligned with a head 62 but on a side opposite housing 120*. Since solenoids 90 are relatively wide members, I find it desirable to provide about three rows of solenoids with the solenoid staggered with respect to each other as seen in FIGS. 1, 2 and 3. The solenoids 90 are provided with plungers 91, each of which, when its solenoid 90 is deenergized, terminates in a position adjacent one of the rear edges 93 of head 62. Of course, the plungers 91 of the first row of solenoids 90 are shorter than the plungers of the next, etc.; so that the ends 92 of all plungers 91 are aligned in close promixity to the rear edges 93 of the heads 62, the construction being such that each plunger 91 is adapted to engage one individual head 62 when its solenoid 90 is energized. Provided that the head 62 is approaching its top dead center position, upon energization of a selected solenoid 90, the force, exerted by the plunger 91 thereof, will act against its head 62 and overcome the spring pressure exerted through piston 94 by spring 95. Therefore, the individual head 62, involved, will be urged forwardly, causing notch 60 to be withdrawn from rod 63 and, simultaneously, causing notch 61 to engage rod 64 as shown in FIG. 2. The needle bar 24 connected to the head 62 involved is now in a long stroke condition.

It is now apparent that each individual needle bar 24 may be shifted from low stroke condition to high stroke condition and back to low stroke condition upon the energizing of its associated solenoid and the deenergization of that solenoid. So long as that solenoid 90 is energized the associated needle bar 24 will remain in its long stroke condition and upon deenergization spring acting through piston 94 returns the head 62 of the needle bar 24 to the position shown in FIG. 3. The shifting of the head 62, however, always takes place as that head 62 approaches top dead center since, only at that time are the rods 63 and 64 aligned with slots 60 and 61. It is apparent, however, that shifting may be accomplished each cycle, if desired.

Next to be considered is the looper mechanism by which the piles or loops are formed and restrained as the needles 51 are retracted. In the present embodiment, I have arranged the loopers to provide a long cut pile and a short loop pile even though it is apparent that other arrangements as to cut or looped pile may be made as desired.

The looper mechanism is driven from main shaft 83 through apparatus best seen in FIGS. 1 and 4. Within the housing 14 is an eccentric cam which is fixed to the end of shaft 83. Surrounding cam 140 is a cam follower 141 provided with a downwardly projecting cam rod 142 which terminates in a journal 143. Journal 143 pivotally receives a stub shaft 144 from which projects a link 145, best seen in FIG. 4. The other end of link 145 is connected to low looper shaft 146. Thus it is seen that upon rotation of shaft 83, eccentric cam 145 will reciprocate cam follower 141, thereby moving cam rod 142 up and down. This movement is transferred through link 145 to shaft 146 so that shaft 146 is rocked back and forth in synchronization with the rotation of shaft 83.

The low looper shaft 146 extends beneath the table 10, below portion 18 and adjacent the path of all needles 51. For each needle 51, shaft 146 is provided with a clamping block 147 to which is adjustably connected, by means of set screw 148, a low looper including an upstanding arm 101 and a rearwardly projecting looper finger 100. Upon rocking of shaft 146, the looper finger 100 is adapted to pass adjacent needle 51 so as to be projected, as shown in FIG. 3, between yarn 53 and needle 51, as needle 51 is moved upwardly. Thus it is seen that with each low stroke of needle 51, looper finger 100 will engage and hold a portion of yarn 53 to form a low loop in fabric 19. However, as the fabric 19 is moved rearwardly, and the finger 100 is rocked in a counterclockwise direction to the position shown in FIG. 2, this loop will be released.

The high looper mechanism, which includes a cutting attachment, is also operated from shaft 146. Referring to FIG. 4, it is seen that from shaft 146 a rocker arm 150 projects rearwardly. The end of rocker arm 150 is pivotally connected to one end of an upwardly projecting link 151. The other end of link 151, in turn, is pivotally connected to one end of an essentially horizontal lever 152. The central portion of lever 152 is secured on the end of a high looper shaft 153, while the other end of lever 153 is provided with a pivotally mounted link 154 which connects to a rocker arm 155 projecting from the end of a cutter shaft 156. It is now seen that upon rocking motion of shaft 146, rocker arm 150 will be moved up and down and this motion will be transmitted through link 151 and lever 152 to rock shaft 153 in an opposite direction to the rocking of shaft 146. Also, lever 152 simultaneously rocks shaft 156, through link 154 and rocker arm 155, to rotate shaft 156 in the same direction that shaft 153 is rotated.

The shafts 153 and 156 project parallel to shaft 146 through the machine beneath portion 18 of table 10 and, like shaft 146, "are provided, respectively, with clamping blocks 157 and 158 adjacent each needle 51. As best seen in FIGS. 2 and 3, each clamping block 153 adjustably carries a looper formed in the shape of -a bell crank and having an upstanding arm 159 carrying a looper 103 which is adapted to project between the needle 51 and yarn 53, only when needle bar 24 is on a high loop stroke. As seen in the drawings, all loopers, such as looper 103, are on the rear side of the path of travel of the needle 51 and on a side opposite looper 100. Thus, when shaft 83 is rotated, loopers 100 and 103 simultaneously project inwardly adjacent the path of needle 51 and then are withdrawn after the needle 51 moves upwardly. Hence, if needle bar 24 is on a long stroke, needle 51 will be projected past looper 103 such that yarn 53 is engaged thereby and if needle bar 24 is on a low stroke, only looper 100 will engage yarn 53-.

In the particular embodiment here disclosed, looper 103 must be provided with a cutting attachment since fabric 19 is moved to the right in FIGS. 2 and 3 and the loops engaged by looper 103 cannot slide therefrom. Accordingly, I have provided a knife blade 102 which is carried by clamping blocks in essentially an upright position adjacent looper "103. The rocking motion of shaft 156 causes knife blade 102 to cut the loops of pile retained on looper 103.

While I have above described a mechanism for forming low looped pile and high cut pile, it will be obvious to those skilled in the :art that by providing two loopers, similar to looper 100, on arm .101, one at the plane of looper 101 and the other at the plane of looper 103, a high-low looped pile could be formed. Also, by providing a pair of loopers similar to looper 103 with associate knife blades, such as blade 102, one above the other, a high-low cut pile fabric could be formed. Since these variations are obvious, they have not been illustrated.

The mechanism for moving the fabric 10 through my machines includes a pair of opposed im-feed rollers 110 which are synchronized to rotate together by meshing gears 170. These rollers 110 are supported on appropriate shafts 171 as illustrated in FIG. 1. The drive mechanism of one of the shafts 171 includes a pulley 172 on shaft 83 in housing 15. Pulley 172 drives, through a continuous belt 112, a second pulley 174. Pulley 174 is connected to a gear reducer 111, the takeoff shaft of which is connected to one of shafts 171. As best seen in FIG. 5, 1a sprocket 175 on one of shafts 171 drives, through a chain 116, a sprocket 176 on the shaft 115. Shaft 115 projects parallel to shafts 171 on the rear side of my machine and, through meshing gears contained in housings 177, drives shafts 178 and 179. Each of shafts 115, 178 and 179 carries a discharge roller (not shown) over which the base fabric 19 is fed. Thus it is seen that the travel of base fabric 19 through my machine is synchronized with the operation of needles 51.

The main drive shaft 83 is rotated from any suitable power source (not shown) by means of a belt (not shown) driving pulley 113. For reinforcement, suitable partitions 180 are provided in the main frame and these partitions each have a main bearing 1 81 journalling shaft 83.

Operation From the foregoing description of my multineedle tufting machine, the operation of the same is apparent. Individual yarns 53 are fed through the tension device 57 and apertures 54 and 54 to the eye 52 of each needle 51, as shown in FIGS. 2 and 3. Next base fabric 19 is fed between rollers 110 and across table 10, then through the rollers of shafts 115, 178 and 179, passing first over the roller of shaft 178, then under the roller of shaft 115 and thereafter over the roller of shaft 179.

The machine may then be started by rotating pulley 113 to rotate shaft 83, so as to drive through belt 112 and gear reducer 111, the rollers 110 to feed fabric 19 into the machine. Simultaneously, of course, the rollers 8 of shafts 115, 178 and 179 will be rotateds'o that the fabric =19 is progressively fed over table With the rotation of shaft -83, cams 82 and 140 are rotated to impart simultaneous 'r'eciprocativ'e motion to pitmans 22 and cam rod 142. The movement of pitrnans 22 will in turn rock arms 65 upwardly and downwardly about pivot shaft 66. Also the motion of cam rod 142 will, through movement of the appropriate mecha nism shown in FIG. 4, cause rocking of shafts 146, 153 and 156.

It should be remembered that since none of the solenoids are energized, the force of each spring, such as spring 95, will maintain the notches, such as notch 60, in engagement with rod 63. Thus, in this condition, each needle bar 24 will be reciprocated to provide a short stroke which passes each needle 51 through base fabric 19 such thatat bottom dead center, the eye 52 of each needle 51 will be above looper 103 but below looper as shown in FIG. 2.

As the needle 51 (on short stroke) moves downwardly each of loops 100 and 103 moves inwardly into the path of needle 51. Since, however, needle 51 is carried by needle bar 24 only to a predetermined distance above looper 103, only looper 100 passes between the yarn 53 and needle 51. On the subsequent up stroke, the yarn 53 of needle 51 is engaged and retained by looper 100 until needle 51 is withdrawn from fabric 19. The motion of fabric 19 and the rocking of shaft 146 in a counterclockwise direction during this portion of the cycle will cause the loop thus formed to be released. The cycle is then repeated. In each cycle, a parallel row of loops is formed.

' If at any time any one, several or all of solenoids 90 are actuated, thereby causing the plunger or plungers 91 to move forwardly, pressure will be exerted against the companion head 62 of the particular plunger 91 thus actuated. If the pitmans 22 are not at top dead center, the force urging the head or heads 62 frowardly will be resisted by the front edge 97 of each head 62 striking rod 64. As, however, approximately top dead center is reached, the rod 64 becomes aligned with the notches 61 of each head and the force of the plunger or plungers 91 will overcome the pressure of spring 95, thereby shifting the particular head or heads 62 forwardly,

It is to be noted that, since shifting takes place in the cycle only in the vicinity of the top dead center, the needles 51 will be withdrawn from the fabric during such shifting.

It is also to be noted that the width of each head 62 in the vicinity of rods 63 and 64 is :greater than the distance from rod 63 to rod 64. Thus, at no time is it possible for head 62 to be disengaged from both rods 63 and 64. The distance from the inner edge of notch 60 or 61 to the opposite edge of head 62, however, is less than the distance from rod 63 to rod 64 and hence once notch 60 is engaged by rod 63 or notch 61 is engaged by rod 64, the head 62 will be entirely free from engagement by the unengaged rod.

When shifting has taken place with head 62 being moved forwardly to the position shown in FIG. 2, the higher notch 61 is engaged by bar 64 which is farther from pivot shaft 66. Therefore, in the subsequent stroke of needle bar 24, the needle 51 is inserted through fabric 19 to a greater depth such that at the bottom dead center position, eye 52 of the needle 51 is below looper 103. Thus rather than being engaged by the looper 100, which nevertheless projects between yarn 53 and the needle 51, the lower looper 103 engages yarn 53 and holds the same as the needle 51 is withdrawn from the fabric 19.

Because of the configuration of looper 103 and its actuation and the fact that the fabric 19 is moved from left to right in FIGS. 2 and 3, looper 103 cannot release the, yarn 53 once the same is engaged; hence the loop of yarn 53, retained by looper 103, is cut by action of knife blade 102 passing adjacent looper 103. Thus it is seen that low looped piles and high cut piles may be intermittently formed as a single line of piles is sewn by each needle 51 using yarn 53 and that the parallel rows of piles transversely of the fabric may randomly contain the low looped pile and the high cut pile according to a predetermined pattern.

Upon deenergizing of any of the energized solenoids 90, the force urging the particular plunger 91 against its head 62 is dissipated and hence the force of spring 95 will return that head 62 to its orignal position shown in FIG. 2, such return being accomplished as the pitmans 22 approach top dead center.

Since the only place the needle bar is retained by the rigid frame is at the opening formed by the guide fingers 58 and spacer plates 50, pivoting of needlev bars 24, forwardly or rearwardly, causes little misalignment of needles 51, and such misalignment simply facilitates the engagement of the proper looper 100 or 103.

While I have not disclosed any particular control mechanisms for actuation or deactuation of solenoids 90, such mechanism may include a rotary drum, the periphery of which is insulated at certain places and brushes riding against the drum to make or break the circuit from a source of current to a particular solenoid 90, the brushes each being in series with a solenoid 90. Other and varied forms of electrical and mechanical control mechanisms may be employed, if desired.

It will be obvious to those skilled in the art that many variations may be made in the embodiment here chosen for the purpose of illustrating the present invention; parts may be reversed, separated or combined, and full resort may be had to equivalents without departing from the scope of my invention as defined by the appended claims.

I claim:

1. In a method of forming a design in tufted fabrics, the steps of successively inserting loops of yarn through a base fabric while maintaining said base fabric in a prescribed and fixed plane, inserting certain of said successive loops through and beyond the extent of insertion of other loops according to a predetermined design, restraining each loop against withdrawal from the fabric substantially the full extent of its insertion and releasing the restrained loops.

2. In a method of forming a design in tufted fabrics, the steps of forming parallel piles by simultaneously inserting substantially aligned loops of yarn through a base fabric while maintaining said base fabric in a prescribed and fixed plane, inserting certain of said loops through and beyond the extent of insertion of other loops according to a predetermined design, restraining the loops against withdrawal from the fabric substantially the full extent of their insertion and releasing the restrained loops' 3. In a method of forming a design intufted fabrics, the steps of forming parallel adjacent rows of piles by successively inserting a plurality of transversely aligned loops of yarn through a base fabric while maintaining said base fabric in a prescribed and fixed plane, inserting certain successive loops through and beyond the extent of insertion of other loops according to a predetermined design, restraining each loop against Withdrawal from the fabric substantially the full extent of its insertion, the extent of insertion of the successive loops of such adjacent rows of piles being variable, each row including successive loops of uniform extent of insertion and releasing the restrained loops.

4. In a method of continuously forming a pile fabric characterized by a design formed by varying extent of loop material from the base fabric, the step of successively and continuously inserting a single yarn through the base fabric to varying extent with respect to the fabric according to a prescribed pattern while maintaining said fabric in a prescribed and fixed plane.

5. In a method of continuously forming a pile fabric characterized by a design formed by various height piles in the base fabric, the steps of continuously inserting parallel rows of loops to varying extent through the fabric while maintaining said fabric in a prescribed and fixed plane, restraining each loop against withdrawal from the extent of its original penetration, cutting certain of said loops as they are restrained and releasing said loops.

6. In a method of continuously forming a pile fabric characterized by a design formed by various height piles in the base fabric, the steps of continuously inserting parallel rows of loops to varying extent through the fabric while maintaining said fabric in a prescribed and fixed plane, and restraining each loop against withdrawal from the extent of its orignal penetration, so that some of the loops of each row are of uniform extent, and some of the loops of some rows are of varying extent from the parallel loops of adjacent rows and releasing the restrained loops.

7. In a continuous method of forming variable height piles in a base fabric while maintaining said fabric in a prescribed and fixed plane, the steps of inserting a first loop of yarn through the fabric to a predetermined extent, engaging the end of the bite of said first loop to restrain such loop at the approximate extent of its insertion, inserting said yarn to a greater predetermined extent to form an adjacent loop of greater extent than said first loop, and engaging the end of the bite of said adjacent loop to restrain such adjacent loop at the approximate extent of its insertion.

8. In a method of forming a pile fabric wherein a predetermined design is defined by intermixed cut piles and looped piles comprising the steps of moving a base fabric in a predetermined path while maintaining said fabric in a prescribed and fixed plane, simultaneously inserting a plurality of loops of yarns into said base fabric to different predetermined depths to form a row of parallel loops of different heights, restraining said loops, and cutting the loops of a certain predetermined height as the same are restrained to form cut pile of said predetermined height intermixed throughout said row with the remaining uncut loops.

9. In a multi-needle tufting machine, means for passing a base fabric therethrough, means for supporting said base fabric in a prescribed and fixed plane as said fabric passes therethrough, a needle mounted for reciprocation to successively penetrate a base fabric and variable stroke means for reciprocating said needle and for varying the amplitude of stroke of the needle as it is reciprocated.

10. In a multi-needle tufting machine, means for passing a base fabric therethrough, means for supporting said base fabric in a prescribed and fixed plane as said fabric passes therethrough, a needle mounted for reciprocation to successively penetrate a base fabric, variable stroke means for reciprocating said needle and for varying the amplitude of stroke of the needle as it is reciprocated, and a drive element operable at a uniform rate of motion for driving said variable stroke means.

11. In a tufting machine, means for passing a base fabric therethrough, a needle mounted for reciprocation to successively penetrate said base fabric, a drive element operable at a uniform rate of motion and a plurality of needle engaging elements driven by said driving means at different amplitudes of motion, said needle being selectively engageable with any one of said elements to be reciprocated thereby with a stroke commensurate with the amplitude of motion of the element engaged.

12. In a tufting machine, means for passing a base fabric therethrough, a needle mounted for reciprocation to successively penetrate a base fabric, a drive element operable at a uniform rate of motion, a pair of needle engaging elements reciprocatable by said drive element at different amplitudes of motion, said needle being selectively engageable with one or the other of said elements to be reciprocated thereby with a stroke commensurate with the amplitude of reciprocation of the element engaged, and means for shifting the engagement of said l l needle between said elements during the reciprocation of said elements.

13. In a sewing machine having a needle, variable stroke mechanism including a needle reciprocating frame, means for oscillating said frame with a uniform motion, a plurality of spaced needle engaging means carried by said frame to be moved by said frame with individual amplitudes of motion in response to uniform motion of said frame, shift means for selectively engaging said needle with said needle engaging means, said shift means including a needle head transversely movable with respect to the line of needle reciprocation and selectively engageable at the opposite extremes of its transverse motion with different needle engaging means, and means for actuating said needle head.

14. In a sewing machine having a needle, variable stroke mechanism including a needle reciprocating frame, means for oscillating said frame with a uniform motion, a plurality of space needle engaging means carried by said frame to be moved by said frame with individual amplitudes of motion in response to uniform motion of said frame, shift means for selectively engaging the needle with said means carried by the frame, said shift means including a needle head transversely movable with respect to the line of needle reciprocation and selectively engageable at the opposite extremes of its transverse motion with different needle engaging means and preselectable remotely controlled means for transversely moving the needle head.

15. In a pattern tufting machine a frame, a row of tufting needles mounted for reciprocation in said frame, means for supporting a base fabric in a prescribed and fixed plane beneath said needles, means for passing a base fabric beneath said needles on said supporting means to receive loops of yarn upon penetration thereof by the needles as they are reciprocated and means for selectively altering the depth of penetration of said needles as the needles are reciprocated to vary the length of loops formed thereby.

16. In a pattern tufting machine a reciprocating frame, a row of essentially aligned tufting needles carried for reciprocation by said frame, means for supporting a base fabric in a prescribed and fixed plane beneath said needles, means for passing a base fabric beneath said needles on said supporting means to receive loops of yarn upon penetration thereof by the needles as they are reciprocated and means associated with said needles for individually altering the amplitude of reciprocation of said needles as the needles are reciprocated to vary the length of loops formed thereby.

17. In a pattern tufting machine a reciprocating frame, a longitudinal row of tufting needles carried for reciprocation by said frame, means for supporting a base fabric in a prescribed and fixed plane beneath said needles, means for .passing a base fabric beneath said needles on said supporting means to receive loops of yarn upon penetration thereof by the needles as they are reciprocated, means associated with said needles for individually altering the amplitude of reciprocation of individual needles to vary the length of loops formed thereby, said last mentioned means being preselectable and remotely controlled to provide uniform reciprocation of all needles simultaneously and to change the amplitude of reciprocation of selected needles during operation of the needles according to a prescribed pattern.

18. A pattern tufting machine including a frame structure, a row of essentially aligned tufting needles mounted for reciprocation in said frame structure, means for passing a base fabric beneath said needles to receive loops of yarn upon penetration thereof by the needles as they are reciprocated, a pivoted needle reciprocating frame, means to oscillate said needle reciprocating frame at a uniform stroke, individual means selectively engageable by said needles and carried by said needle reciprocating frame for movement in individual paths of differing amplitude with the uniform stroke of said needle reciprocating frame and means for selectively engaging certain of said needles with a selected one of said individual means to selectively control the amplitude of reciprocation of the individual needles, said individual means including a pair of longitudinally extending parallel rods carried by the frame and spaced thereon at different radial distances from the axis of oscillation of said frame.

19. In a tufting machine having a reciprocating needle and wherein a base fabric is passed beneath said reciprocating needle which inserts successive loops formed from a length of yarn into said base fabric, the combination therewith of a needle bar carrying said needle, there being provided on said needle bar a plurality of spaced engaging means, reciprocating means having different amplitudes and engageable selectively with one of said engaging means to determine the depth of penetration of said needle, and means for engaging the loops as they are formed.

20. An independently variable stroke multiple needle tufting machine comprising a frame having a table thereon, means for moving base fabric across said table, there being provided in said frame a plurality of apertures adjacent and above said table, a plurality of needle bars slideably carried within said apertures, needles on the ends of said needle bars for insertion through said base fabric, transversely shiftable heads on the other ends of said needle bars provided with notches on opposite sides of said heads, a pair of actuating means respectively mounted adjacent said opposite sides of said heads, means for reciprocating said actuating means, one of said actuating means having an amplitude different from the other of said actuating means, and means for selectively urging individual of said heads transversely of said actuating means to cause selective engagement of said notches and said actuating means.

21. In a tufting machine having a frame structure with a plurality of reciprocatable needle bars carried by said frame structure and needles carried by said needle bars and carrying yarn for insertion to a predetermined depth through a base fabric below said needles as said base fabric is passed through the machine, the combination therewith of means connected to said frame structure for individually varying the stroke of said needle bars as said needle bars are reciprocated to insert the needles thereof to depths in said fabric different from said predetermined depth and looper means carried by said frame structure below said base fabric for engaging the loops of yarn formed by the needles.

22. The structure defined in claim 21 wherein said looper means include a pair of synchronized loopers adapted to project into the path of travel of the loop of one of said needles at different levels with respect to said fabric, one of said pair of loopers engaging yarn inserted by one of said needles to said predetermined depth, the other of said pair of loopers engaging yarn inserted by said one of said needles to said depth different from said predetermined depth.

23. The structure defined in claim 22 wherein each of said needle bars is provided with a pair of notches, said means for individually varying the stroke of said needle bars including a pair of reciprocating means respectively associated with said pair of notches, and means for simultaneously engaging one of said pair of reciprocating means with its associated notch as the other of said pair of reciprocating means is disengaged from its associated notch and vice versa. 1

24. The structure defined in claim 23 wherein said notches are on opposite sides of each of said needle bars and are provided at different positions longitudinally of said needle bars.

25. A method of tufting comprising supporting a base fabric and feeding it in one direction, reciprocating a needle which carries yarn through the base fabric, varying th amplitude of stroke of the needle according to a predetermined pattern to provide a long stroke which inserts the yarn a predetermined long distance through the base fabric and a short stroke which projects the yarn a predetermined short distance through the base fabric to form long and short loops in succession upon the base fabric and moving the loops in the same direction with the base fabric, supporting a pair of reciprocatory loopers upon the same side of the fabric as the loops, moving the loopers so that the free end of one looper projects into a short loop and the free end of the other looper projects into a long loop, holding the loops by the loopers until the loops are formed and thereafter releasing the loops.

26. A method of tufting comprising supporting a base fabric and feeding it in one direction, reciprocating a needle which carries yarn through the base fabric, varying the amplitude of stroke of the needle according to a predetermined pattern to provide a long stroke which inserts the yarn a predetermined long distance through the base fabric and a short stroke which projects the yarn a predetermined short distance through the base fabric to form long and short loops in succession upon the base fabric and moving the loops in the same direction with the base fabric, supporting a pair of reciprocatory loopers upon the same side of the fabric as the loops, moving the loopers so that the free end of one looper projects into a short loop and the free end of the other looper projects into a long loop, holding the loops by the loopers until the loops are formed, severing the loops upon said other looper after they have been formed and releasing the loops held by said one looper after they have been formed.

27. In a method of forming patterns with piles of yarn in a base fabric comprising substantially simultaneously inserting a plurality of transversely aligned pile loops in a base fabric to form a first row of transversely aligned pile loops while maintaining said base fabric in a prescribed and fixed plane, furnishing thread for the successive formation of additional rows of aligned loops spaced from and generally parallel to said first row of loops, and repeating said loop forming operation, the steps of inserting certain selected loops beyond the insertion of the other loops corresponding to the demands of a. prescribed pattern to thereby provide long loops corresponding to the length of insertion of said certain loops.

28. The method of claim 27 including the step of severing the long loops after their formation.

References Cited by the Examiner UNITED STATES PATENTS 876,562 1/1908 Kleutgen 112-79 1,907,292 5/ 1933 Gladish 11279.6 1,909,531 5/1931 Gladish 11279.6 1,984,331 12/1934 Boyce. 2,365,013 12/ 1944 Sharkey et a1 11279.6 2,533,420 12/ 1950 Blumfield 11280 2,824,532 2/ 8 Scheibel 112-221 2,832,302 4/1958 Gegauf 112158 2,837,045 6/1958 Gifford 112-80 2,842,080 7/ 195 8 Hoeselbarth 11279.6 2,860,588 11/1958 Penman 112-79.6 2,879,728 3/ 1959 McCntchen 112-79 2,882,845 4/ 1959 Hoeselbarth 112--79.6 2,961,982 11/1960 Wear 11279.6 3,052,198 9/1962 Whitney 1l2-79 FOREIGN PATENTS 25,147 11/ 1902 Great Britain.

JORDAN FRANKLIN, Primary Examiner.

DAVID I WILLIAMOWSKY, THOMAS J, HICKEY,

Examiners.

M. J. COLITZ, J. R. BOLER, Assistant Examiners. 

1. IN A METHOD OF FORMING A DESIGN IN TUFTED FABRICS, THE STEPS OF SUCCESSIVELY INSERTING LOOPS OF YARN THROUGH A BASE OF FABRIC WHILE MAINTAINING SAID BASE FABRIC IN A PRESCRIBED AND FIXED PLANE, INSERTING CERTAIN OF SAID SUCCESSIVE LOOPS THROUGH AND BEYOND THE EXTENT OF INSERTION OF OTHER LOOPS ACCORDING TO A PREDETERMINED DESIGN, RESTRAINING EACH LOOP AGAINST WITHDRAWAL FROM THE FABRIC SUBSTANTIALLY THE FULL EXTENT OF ITS INSERTION AND RELEASING THE RESTRAINED LOOPS. 